Method and apparatus for reducing risk that a thrown toy will injure an animal

ABSTRACT

A method and apparatus for reducing the risk that a thrown toy will injure an animal. The apparatus consists of a toy which when thrown bounces erratically, which compressively elastically deforms, which includes a soft fabric outer surface that compresses to absorb blows, and which can withstand being bitten or chewed by a dog.

This is a continuation-in-part of patent application Ser. No. 10/854,548filed May 26, 2004 now U.S. Pat. No. 7,201,117 and is in the U.S. Patentand Trademark Office.

This invention relates to toys.

More particularly, the invention relates to a toy for an animal.

In a further respect, the invention relates to an animal toy which whenthrown can bounce erratically, which minimizes the probability of harmto an animal trying to catch a toy which has been thrown, which issymmetrical but is shaped to include points at varying distances awayfrom the center of the toy to enable the toy to bounce erratically,which is permanently sealed so that the toy repeatedly compressivelyelastically deforms and bends in the same predictable manner, whichincludes a soft fabric outer surface that compresses to absorb blows andsoften the impact when the toy hits an animal or other surface, andwhich can withstand being bitten or chewed by a dog and continue tofunction.

A wide variety of animal toys are known. One kind of toy is made of hardrubber and comes in a variety of shapes. For example, a dog bone made ofhard, tough rubber has long been sold in retail outlets. A hard, toughrubber is utilized to make it difficult for a dog to chew through thebone. The rubber also adds weight to the toy, permitting the toy to bethrown long distances. Finally, the rubber material used to make the toyalso enables the toy bone to bounce into the air. Dogs like chasingbouncing toys. While this type of toy is without question resistant tobe damaged or chewed up, the toy is also dangerous. If the toy whenthrown bounces into a dog, the toy can, due to its hardness, injure theanimal. Worse, if the bone is thrown in the air and hits the dogstraight away before the bone hits the ground, the dog can also beinjured.

Animal toys can be constructed by attaching sections of felt fabric tothe outer surface of a rubber shell such that the fabric sections areseparated by a seam or strip of rubber or other polymer. In practice,the fabric sections are adhered or otherwise fastened to the rubbershell such that the edge of one piece of fabric is adjacent the edge ofa second piece of fabric. The adjacent fabric edges define a rough seamline. A strip of rubber tape is attached to the pieces of fabric suchthat the tape covers the seam line. After the tape is attached, theentire rubber shell—fabric piece—rubber tape assembly is placed in amold to melt and cure the rubber tape. A particular problem associatedwith this procedure is that the edges of the top and bottom portions ofthe mold tend to engage and stick to the rubber tape, pulling a largeportion of the tape off the seam line.

One type of retrieval training toy comprises a piece of rope or cordattached to a plastic body or to a body comprises of a small canvas bagfilled with a pliable material like sawdust, sand, small pieces ofpaper, etc. A trainer or other individual utilizes a retrieval toy bygrasping the piece of rope and using the rope to throw the toy. The dogor other animal retrieving the toy takes the rope or body and carriesthe toy back to the trainer. These kinds of retrieval training toysordinarily are not sealed or do not bounce

Accordingly, it would be highly desirable to provide an improved dog'stoy which can be thrown a long distance to bounce in an erratic patternliked by dogs while producing only a small risk that the toy will injurea dog. It would also be highly desirable to provide an improved methodfor molding a dog's toy to minimize the quantity of rubber tape pulledoff the seam line of the toy during molding of the toy to soften andcure the rubber tape.

Therefore, it is a principal object of the instant invention to providean improved toy.

A further object of the invention is to provide an improved animal toywhich reduces the risk that the toy will, when thrown, injure an animalchasing the toy.

Another object of the invention is to provide an improved animal toywhich elastically compresses and bends to minimize the risk of injury toan animal.

Still another object of the invention is to provide an improved methodof producing an animal toy which reduces the likelihood that polymerseam tape will significantly damaged during molding.

Still a further object of the invention is to provide an improvedretrieval toy which includes a throw-rope attached to a toy body, whichis sealed, and which bounces.

Yet another object of the invention is to provide an improved method formanufacturing a pliable retrieval toy of the type including a throw-ropeattached to a toy body.

These and other, further and more specific objects and advantages of theinvention will be apparent to those skilled in the art from thefollowing detailed description thereof, taken in conjunction with thedrawings, in which:

FIG. 1 is a perspective view of a hollow elastic fabric-covered toyconstructed in accordance with the principles of the invention;

FIG. 2 is a perspective view of another hollow elastic fabric-coveredtoy constructed in accordance with the principles of the invention;

FIG. 3 is a perspective view of still another hollow, elasticfabric-covered toy constructed in accordance with the principles of theinvention;

FIG. 4 is a side elevation view of the toy of FIG. 1 bouncingend-over-end in a constant fixed direction after being thrown andlanding on the ground;

FIG. 5 is a block flow diagram illustrating a method for producing ananimal toy in accordance with the invention;

FIG. 6 is a top view of the top and bottom halves used in forming a toyin accordance with the method of FIG. 5;

FIG. 7 is a side elevation assembly view of the top and bottom halves ofFIG. 6 further indicating where adhesive is applied to affix the top andbottom halves to one another to form a seam line;

FIG. 8 is a side elevation view illustrating the top and bottom halvesof FIGS. 6 and 7 after assembly, and indicating application of polymertape along the seam line and of felt covers overlapping the polymer tapeto produce a moldable member;

FIG. 9 is a section view of the moldable member of FIG. 8 taken alongsection lines 9-9 thereof and illustrating the molding of the moldablemember to draw together the edges of the felt covers and to soften andcure the polymer tape;

FIG. 10 is a perspective assembly view illustrating another embodimentof the invention utilized in training a dog or other animal or utilizedduring play with an animal;

FIG. 11 is a perspective view illustrating the training toy of FIG. 10fully assembled;

FIG. 12 is a perspective view illustrating a molded rubber componentutilized in producing the training toy of FIG. 10;

FIG. 13 is a block flow diagram illustrating a method for fabricatingthe toy of FIGS. 10 to 12;

FIG. 14 is a perspective view illustrating an alternate embodiment ofthe invention;

FIG. 15 is a perspective view illustrating a sound device that can beutilized in the animal toy of FIG. 14;

FIG. 16 is a perspective view illustrating another sound device that canbe utilized in the animal toy of FIG. 14;

FIG. 17 is a section view illustrating additional construction detailsof the sound device of FIG. 16 and taken along section line 17-17thereof;

FIG. 18 is a section view illustrating a method for producing an animaltoy comparable to that illustrated in FIG. 14;

FIG. 19 is a section view further illustrating the method of FIG. 18 forproducing an animal toy;

FIG. 20 is a section view further illustrating the method of FIG. 18 forproducing an animal toy;

FIG. 21 is a section view further illustrating the method of FIG. 18 forproducing an animal toy;

FIG. 22 is a section view illustrating another method for producing theanimal toy of FIG. 14;

FIG. 23 is a section view further illustrating the method of FIG. 22 forproducing an animal toy;

FIG. 24 is a section view further illustrating the method of FIG. 22 forproducing an animal toy;

FIG. 25 is a section view further illustrating the method of FIG. 22 forproducing an animal toy;

FIG. 26 is a section view illustrating still another method forproducing an animal toy comparably to the toy of FIG. 14;

FIG. 27 is a section view further illustrating the method of FIG. 26 forproducing an animal toy;

FIG. 28 is a section view further illustrating the method of FIG. 26 forproducing an animal toy;

FIG. 29 illustrates an alternate method for producing an animal toy inaccordance with the principles of the invention;

FIG. 30 illustrates a further alternate method for producing an animaltoy in accordance with the invention;

FIG. 31 illustrates another alternate method for producing an animal toyin accordance with the invention; and,

FIG. 32 illustrates still a further alternate method for producing ananimal toy in accordance with the invention.

Briefly, in accordance with the invention, an improved animal toy isprovided. The toy includes a compressibly elastically deformable hollowthin-walled rubber core sealingly circumscribing and enclosing aselected compressible gaseous volume. The rubber core includes a center,an outer surface, a wall less than about five-sixteenths of an inchthick, and points on the outer surface at varying distances from thecenter. A felt cover is affixed to the outer surface of the core. Atleast one elongate strip of material extends over the outer surface as aline of demarcation to separate the felt cover into at a least twoareas, one on either side of the strip of material.

In another embodiment of the invention, an improved animal toy isprovided. The toy includes a compressibly elastically deformable hollowthin-walled rubber core sealingly circumscribing and enclosing aselected compressible gaseous volume. The rubber core includes a center;an outer surface; a wall less than about five-sixteenths of an inchthick; points on the outer surface at varying distances from the center;and, an inner wall portion circumscribing an aperture extendingcompletely through the core. A felt cover is affixed to the outersurface of the core.

In a further embodiment of the invention, an improved animal toy isprovided. The toy includes a compressibly elastically deformablethin-walled hollow symmetrical rubber core sealingly circumscribing andenclosing a selected compressible gaseous volume. The rubber coreincludes a center; an outer surface; a wall less than aboutfive-sixteenths of an inch thick; and, points on the outer surface atvarying distances from the center. A felt cover is affixed to the outersurface of the core. The symmetrical core is shaped and dimensioned suchthat the toy can be thrown to bounce along a straight line, and suchthat the direction of travel of the toy changes from bounce to bounce.

In still another embodiment of the invention, an improved animal toy isprovided. The toy includes a compressibly, elastically deformablethin-walled hollow rubber core sealingly circumscribing and enclosing aselected compressible gaseous volume. The rubber core includes a center;an outer surface; a wall less than about five-sixteenths of an inchthick; points on the outer surface at varying distances from the center;and, an inner wall portion circumscribing an aperture extendingcompletely through the core. The core is shaped and dimensioned suchthat the toy when thrown randomly bounces erratically. A felt cover isaffixed to the outer surface of the core. A length of rope extendsthrough the aperture such that the rope can be grasped to throw the toy.

In yet another embodiment of the invention, an improved animal toy isprovided. The toy includes a compressibly, elastically deformablethin-walled hollow rubber core sealingly circumscribing and enclosing aselected compressible gaseous volume. The rubber core includes a center;an outer surface; a wall less than about five-sixteenths of an inchthick; and, points on the outer surface at varying distances from thecenter. The core is shaped and dimensioned such that the toy when thrownrandomly will bounce erratically. A felt cover is affixed to the outersurface of the core and includes a plurality of fibers forming a softcompressible layer adjacent the outer surface.

In still yet another embodiment of the invention, an improved animal toyis provided. The toy includes an elongate compressibly, elasticallydeformable bendable thin-walled hollow rubber core sealinglycircumscribing and enclosing a selected compressible gaseous volume. Thecore includes a center; an outer surface; a wall less than aboutfive-sixteenths of an inch thick; and, points on the outer surface atvarying distances from the center. The core is shaped and dimensionedsuch that the toy when thrown randomly will bounce erratically. A feltcover is affixed to the outer surface of the core and includes aplurality of fibers forming a soft compressible layer adjacent the outersurface.

In a further embodiment of the invention, an improved animal toy isprovided. The improved animal toy includes a compressibly elasticallydeformable hollow thin-walled rubber core sealingly circumscribing andenclosing a selected compressible gaseous volume and including a center,an outer surface, a wall less than about eight millimeters thick, andpoints on the outer surface at varying distances from the center;includes a felt cover affixed to the outer surface of the core andhaving a selected thickness, the ratio of the thickness of said feltcover to the thickness of said wall being in the range of 1:6 to 1:0.15;and, includes at least one elongate strip of material extending over theouter surface as a line of demarcation to separate the felt cover intoat least two areas, one on either side of the strip of material.

In another embodiment of the invention, an improved animal toy isprovided. The improved toy includes a compressibly elasticallydeformable hollow thin-walled rubber core sealingly circumscribing andenclosing a selected compressible gaseous volume and including a center;an outer surface, a wall less than about five-sixteenths of an inchthick; points on the outer surface at varying distances from the center;and, at least one arcuate outer edge generally having a radius of atleast three-quarters of an inch; and, a felt cover affixed to the outersurface of the core. The felt cover has a thickness greater than abouttwo millimeters.

In still a further embodiment of the invention, an improved animal toyis provided. The improved animal toy includes a compressibly elasticallydeformable thin-walled hollow symmetrical rubber core sealinglycircumscribing and enclosing a selected compressible gaseous volume andincluding a center, an outer surface, a wall less than aboutfive-sixteenths of an inch thick, and points on the outer surface atvarying distances from the center. The improved toy also includes atleast one arcuate edge including an area of weakness that reduces theforce required to deform the edge; and, a felt cover affixed to theouter surface of the core.

In yet another embodiment of the invention, an improved method forproducing an animal toy is provided. The improved method includes thesteps of forming the top half of the toy; forming the bottom half of thetoy; fastening together the top half and the bottom half along a seamline to form a unitary member; applying polymer tape along the seamline; applying a felt cover to the top half such that at least a portionof the edge of the cover overlaps the polymer tape; applying a feltcover to the bottom half such that at least a portion of the edge of thecover overlaps the polymer tape, the unitary member, polymer tape andfelt covers collectively forming a moldable member; and, molding themoldable member to soften and cure the polymer tape and to draw togetherthe edges of the felt covers.

In another embodiment of the invention, an improved animal toy isprovided. The toy includes a compressibly elastically deformable hollowthin-walled elastomer core sealingly circumscribing and enclosing aselected compressible gaseous volume and including a center, an outersurface, a wall less than about eight millimeters thick, and points onthe outer surface at varying distances from the center; includes afabric cover affixed to the outer surface of the core and having aselected thickness, the ratio of the thickness of the fabric cover tothe thickness of the wall being in the range of 1:6 to 1:0.15; and,includes at least one elongate strip of material extending over theouter surface as a line of demarcation to separate the fabric cover intoat least two areas, one on either side of the strip of material.

In a further embodiment of the invention, an improved method forproducing an animal toy is provided. The improved method includes thesteps of forming the top half of the toy; forming the bottom half of thetoy; fastening together the top half and the bottom half along a seamline to form a unitary member; applying polymer tape along the seamline; applying a fabric cover to the top half such that at least aportion of the edge of the cover overlaps the polymer tape; applying afabric cover to the bottom half such that at least a portion of the edgeof the cover overlaps the polymer tape, the unitary member, polymer tapeand fabric covers collectively forming a moldable member; and, moldingthe moldable member to soften and cure the polymer tape and to drawtogether the edges of the fabric covers.

In still another embodiment of the invention, an improved animal toy isprovided. The toy includes a first compartment; a second compartment; adiaphragm separating the first and second compartments; a compressiblyelastically deformable hollow elastomer thin wall less than about eightmillimeters thick, having an outer surface, having a center, havingpoints on the outer surface at varying distances from the center, andsealingly circumscribing and enclosing a selected compressible gaseousvolume in the first compartment, and circumscribing and at leastpartially enclosing the second compartment; an aperture formed throughthe thin wall in the portion of the wall circumscribing the secondcompartment; a rope having an intermediate portion, a proximate endpositioned outside the first and second compartment, and a distal endformed as an anchor and positioned in the second compartment such thatthe intermediate portion of the rope extends from the distal endoutwardly through the aperture to the proximate end; and, a fabric coveraffixed to the outer surface of the wall.

In still a further embodiment of the invention, an improved method forproducing an animal toy is provided. The method includes the steps offorming the top half of the toy, the top half including a firstdiaphragm portion dividing the top half into two portions; forming thebottom half of the toy, the bottom half including a second diaphragmportion dividing the bottom half into two portions and shaped to joinwith the first diaphragm portion when the halves are mated; providing alength of rope with a proximate end and a distal end; forming an anchorat the distal end; fastening together the top half and bottom half alonga seam line to form a unitary member with the first and second diaphragmportions in registration and joined to divide said unitary member intoat least a first sealed compartment and a second unsealed compartment,with the anchor in the unsealed compartment, and with the proximate endpositioned outside the first and second compartments and the unitarymember; and, applying a fabric cover to the unitary member.

In yet another embodiment of the invention, an improved animal toy isprovided. The toy includes a compressibly deformable thin wallcircumscribing and enclosing a selected volume at least partially filledwith a gas, the volume including a center, the wall including an outersurface and being less than about eight millimeters thick, the outersurface including points at varying distances from the center; anaperture formed through the wall; and, a rope having an intermediateportion, a proximate end positioned outside the core, and a distal endformed as an anchor and positioned inside the wall that the intermediateportion of the rope extends from the distal end outwardly through theaperture to the proximate end, the anchor being shaped and dimensionedto prevent the anchor from passing through the aperture.

In another embodiment of the invention, an improved method for producingan animal toy is provided. The method includes the steps of forming thetop half of the toy; forming the bottom half of the toy; providing adiaphragm portion; providing a length of rope with a proximate end and adistal end; forming an anchor at the distal end; assembling the tophalf, the bottom half, and the diaphragm to form a unitary member. Inthe unitary member, the diaphragm divides the unitary member into atleast a first sealed compartment and a second unsealed compartment, theanchor is in the unsealed compartment, and, the proximate end ispositioned outside the first and second compartments and the unitarymember. The method also includes the step of applying a fabric cover tothe unitary member. When the diaphragm portion is supplied prior toassembly of the unitary member, the diaphragm portion can be an integralportion of the top half or the bottom half or can be separate from thetop half and the bottom half.

In a further embodiment of the invention, an improved method forproducing an animal toy is provided. The method includes the steps offorming the top half of the toy; forming the bottom half of the toy;fastening together the top half and the bottom half along a seam line toform a unitary member; applying a first fabric cover to the top half,the cover including an edge; applying a second fabric cover to thebottom half, said second cover including an edge; and, molding the tophalf, bottom half, and fabric covers to draw together the edges of thefabric covers.

In still another embodiment of the invention, an improved animal toy isprovided. The toy includes a first compartment; a second compartment; adiaphragm separating the first and second compartments; and, acompressibly elastically deformable hollow elastomer thin wall. The wallis less than about eight millimeters thick; has an outer surface; has acenter; has points on the outer surface at varying distances from thecenter; sealingly circumscribes and encloses a selected compressiblegaseous volume in the first compartment; and, circumscribes and at leastpartially encloses the second compartment. The toy also includes atleast two apertures formed through the thin wall in the portion of thewall circumscribing the second compartment; and, a rope. The rope has anintermediate portion extending through the apertures; has a first endpositioned outside the first and second compartments; and, has a secondend positioned outside of the first and second compartments. The toyalso includes a fabric cover affixed to the outer surface of the wall.

In still a further embodiment of the invention, we provide an improvedanimal toy. The toy includes a compressibly elastically deformablehollow thin-walled elastomer core circumscribing and enclosing aselected compressible gaseous volume and including a center, an outersurface, a wall less than about eight millimeters thick, and, points onthe outer surface at varying distances from the center; includes afabric cover affixed to the outer surface of the core and having aselected thickness, the ratio of the thickness of the fabric cover tothe thickness of the wall being in the range of 1:6 to 1:0.15; includesat least one elongate strip of material extending over the outer surfaceas a line of demarcation to separate the fabric cover into at least twoareas, one on either side of said strip of material; includes at leastone aperture formed through the core; and, includes a hollow sounddevice mounted in the core for producing a sound audible to a dog whenair travels through the sound device at a selected rate of flow.

In yet a further embodiment of the invention, we provide an improvedmethod for producing an animal toy, including the steps of forming thecore of the toy; applying a fabric cover to the core; forming anaperture through the core; inserting in the aperture a hollow sounddevice to produce a sound audible to a dog when air travels through thesound device at a selected rate of flow.

In yet another embodiment of the invention, we provide an improvedanimal toy. The animal toy includes a first compartment; a secondcompartment; a diaphragm separating the first and second compartments;and, a compressibly elastically deformable hollow elastomer thin wallless than about eight millimeters thick. The wall has an outer surface,has a center, circumscribes and encloses a selected compressible gaseousvolume in the first compartment, and circumscribes and at leastpartially encloses the second compartment. The toy also includes atleast one aperture formed through the thin wall in a portion of the wallcircumscribing the second compartment; and, a rope. The rope has anintermediate portion; a proximate end positioned outside the first andsecond compartments; and, a distal end formed as an anchor andpositioned in the second compartment such that the intermediate portionof the rope extends from the distal end outwardly through the apertureto the proximate end. The toy also includes a fabric cover affixed tothe outer surface of the wall; at least one aperture formed through thethin wall in a portion of the wall circumscribing the first compartment;and, a hollow sound device for producing a sound audible to a dog whenair travels through the sound device at a selected rate of flow.

In yet still a further embodiment of the invention, we provide animproved method for producing an animal toy. The method includes thesteps of forming the core of the toy; applying with heat and pressure afabric cover to the core; forming an aperture through the core and thefabric; inserting in the aperture a hollow sound device to produce asound audible to a dog when air travels through the sound device at aselected rate of flow; and, covering the hollow sound device with fabricmaterial.

In yet still another embodiment of the invention, we provide an improvedanimal toy including a compressibly elastically deformable thin-walledpolymer core circumscribing and enclosing a selected compressiblegaseous volume and including a center, an outer surface, and a wall;including a fabric cover affixed to the outer surface of the core andhaving a selected thickness, the fabric cover including a plurality offibers formed a soft compressible layer adjacent said outer surface;including an aperture formed through the core; and, including a hollowsound device inserted in the aperture to produce a sound audible to adog when air travels through the sound device at a selected rate offlow. The wall of the core has a thickness in the range of 0.0016 m to0.0078 m. The core is shaped and dimensioned such that the toy, whenthrown, will bounce erratically. The ratio of the thickness of saidfabric cover to the thickness of the wall can be in the range of 1:3 to1.5:1. The ratio of the thickness of the fabric cover to the thicknessof the wall can be in the range of 1:2 to 1:1. The felt cover can have athickness greater than about two millimeters. The toy can include anarcuate edge having a radius of at least 01.0188 m. The fabric cover canhave a thickness in the range of 0.002 m to 0.006 m. The core can have athickness in the range of 0.002 m to 0.006 m. The core can besymmetrical.

In a further embodiment of the invention, we provide an improved animaltoy. The toy includes a compressibly elastically deformable hollowthin-walled elastomer core circumscribing and enclosing a selectedgaseous volume and including a center, an outer surface, and a wall; afabric cover affixed to the outer surface of said core and having aselected thickness; at least one elongate strip of material extendingover outer surface as a line of demarcation to separate fabric coverinto at least two areas, one on either side of the strip of material; atleast one aperture formed through said core; and, a temperatureresistant hollow sound device mounted in the core for producing a soundaudible to a dog when air travels through the sound device at a selectedrate of flow.

In another embodiment of the invention, we provide an improved methodfor producing an animal toy. The method includes the steps of formingthe core of the toy with an aperture; inserting a temperature resistantsqueaker the aperture; applying adhesive and a fabric cover to the core;and, heating the core, adhesive, and fabric to an elevated temperaturegreater than two hundred degrees F.

In still a further embodiment of the invention, we provide an improvedmethod for producing an animal toy. The method includes the steps offorming the core of the toy including an aperture, and a thinpuncturable sheet of material covering the aperture; applying a fabriccover to the core; inserting in the aperture a hollow sound device topuncture the sheet and to produce a sound audible to a dog when airtravels through the sound device at a selected rate of flow.

Turning now to the drawings, which describe the presently preferredembodiments of the invention for the purpose of illustrating thepractice thereof and not by way of limitation of the scope of theinvention, and in which like characters refer to corresponding elementsthroughout the several views, FIG. 1 illustrates a toy including ahollow cylindrical rubber core 11. If desired, supporting walls can beformed inside of hollow core 11 much like bulkheads are formed insidethe hollow hull of a ship. Pieces 12, 13 of felt or another desiredfabric are adhesively secured or otherwise affixed to the outercylindrical surface 28 of core 11. Fabric pieces 12, 13 are shaped anddimensioned and applied to surface 28 such that a space or groove ofsubstantially constant width between the pieces 12, 13 is formed. Thistrack is filled with an elastic rubber material to form strip 14.Alternatively, one or more fabric pieces can be utilizes to completecover surface 28, after which a strip 14 of material can be attached onor in the fabric to form a strip 14 dividing the fabric into sections oneither side of the strip 14. Strip 14 presently has a width in the rangeof one-sixteenth to seven-sixteenths (1.5 mm to 10.5 mm) of an inch,preferably one-sixteenth to five-sixteenths (1.5 mm to 7.5 mm) of aninch.

Cylindrical end piece 18 includes rubber piece 19 and fabric piece 20adhesively secured or otherwise secured to piece 19. End piece 18 issecured to circular end surface or lip 22.

Cylindrical end piece 15 includes rubber piece 16 and fabric piece 17adhesively secured or otherwise secured to piece 17. End piece 15 issecured to circular end surface or lip 21.

After end pieces 15 and 18 are secured to the ends of core 11, rubberpieces 19 and 16 and core 11 circumscribe and seal closed cylindricalvolume 29.

The fabric used to cover surface 28 is presently preferably felt becausefelt provides a soft surface which reduces the strength of a blow to ananimal when the toy inadvertently strikes an animal. Felt alsoresiliently compresses to absorb some of the force of the blow. Whileany felt can be utilized, the preferred felt comprises a firm wovencloth of wool or cotton heavily napped and shrunk to form a smoothresilient texture.

The core 11 of the toy of the invention must be fabricated from rubberbecause core 11 must be able to be elastically compressed. As usedherein, the term rubber includes natural or synthetic rubbers andpolymers or other components which produce materials having theproperties of a rubber.

Since the wall of hollow core 11 must have “give”, it is important inthe practice of the invention that the wall be relatively thin. Thethickness, indicated by arrows A in FIG. 1, of the wall of core 11 is inthe range of about one-sixteenth of an inch to five-sixteenths of aninch, preferably one-sixteenth of an inch to three-sixteenths of aninch.

At the same time, the rubber utilized to make core 11 must be relativelytough so that a dog or other animal cannot with its teeth readilypuncture core 11.

Another important feature of the toy of the invention is that core 11must sealingly circumscribe a gaseous volume 29. Volume 29 ordinarily isfilled with air, but nitrogen or any other desired gas can be utilized.It is acceptable for the gas to have some moisture content; however,filling volume 29 with a fluid is not presently preferred because thefluid can add substantial weight to the toy and because the fluid doesnot compress as readily as a gas. After core 11 and end pieces 15 and 18are assembled and sealingly enclose volume 29, additional gas can, ifdesired, be added to volume 29 to pressurize volume 29. Any desiredmethod can be utilized to pressurize volume 29. For example, acomposition can be put into volume 29 during manufacture. After member11 and pieces 15 and 18 are assembled to sealingly enclose volume 29 andenclose the composition in volume 29, the assembled unit is heated tocause the composition to release gas to pressurize volume 29.

Pressurizing volume 29 is preferred because the pressure helps tosupport the wall of core 11 while still not preventing the wall of core11 from being elastically compressed.

The center point 40 of the toy of FIG. 1 is circumscribed by and spacedapart from the cylindrical wall of core 11. Point 40 is also equidistantfrom each end piece 15, 18. The center point of a toy constructed inaccordance with the invention is generally at an average distance frompoints, lines, or angle on the exterior of the toy. It is important thateach toy include points on its exterior which are not equidistant fromthe center point of the toy. This construction insures that the toy willhave the ability to bounce erratically. A toy with all surface pointsequidistant from the center of the toy is not utilized in the practiceof the invention.

As earlier noted, elastic core 11 can be compressed, i.e., thecylindrical wall of core 11 can be elastically pushed inwardly. Anotherimportant feature which can be incorporated into toys constructed inaccordance with the invention is that they can be bent. In FIG. 1 forexample, after the toy is assembled, end piece 18 can be moved in thedirection of arrow L simultaneously with the movement of end 15 in thedirection of arrow M. When an object is bent, part of the object issubject to tensile forces while another opposed part of the object issubjected to compressive forces.

The hollow toy 25 illustrated in FIG. 2 includes a doughnut-shapedrubber core 26 which sealingly encloses gas-filled volume 40. Felt cloth27 or other fabric substantially completely covers the outer surface ofcore 26 in the same manner that cloth pieces 12 and 13 coversubstantially the entire outer surface 28 of the toy shown in FIG. 1.Cylindrical aperture 44 extends completely through toy 25. Knot 41formed in rope 42 does not fit through aperture 25, which permits end 43to be grasped manually so that the rope 42 and toy 25 can be twirled andthrown.

The toy 30 illustrated in FIG. 3 includes three hollow cylindrical legs31, 32, 33 which co-terminate to form a three-legged toy. While theangles between legs can vary and the number of legs in the toy can vary,it is presently preferred that the legs 31 to 33 be normal to eachother.

As used herein, when a toy is thrown “randomly”, the toy is thrownwithout any attempt to control the orientation of the toy in the air.When the toys illustrated in FIGS. 1 to 3 are thrown randomly, it ishighly likely that they will bounce erratically when they hit theground. It is possible, however, for each toy to be thrown so it willnot bounce erratically. For example, as shown in FIG. 4, the toy in FIG.1 can be thrown end-over-end toward the ground in the direction of arrowY, hit the ground, and continue to travel in the direction of arrow D.This does not constitute an erratic bounce because after the toy hitsthe ground it continues to travel in the same direction D.

Similarly, it is possible to throw the toy of FIG. 2 like a frisbee,such that the toy 25 hits or lands on the ground flat on one of its twoopposed circular faces and stops dead. This does not constitute anerratic bounce because the toy 25 does not bounce. Throwing the toy toaccomplish such a landing is difficult at best. Alternately, toy 25 canbe thrown in a vertical orientation which causes it to land on edge onthe ground and roll in a straight line. This is difficult to accomplishon a consistent basis, especially if rope 42 is still in the toy 25 whenit lands. To insure that rope 42 stays in the toy, a knot can also beformed in end 43 which will not pass through aperture 44.

Throwing toy 30 of FIG. 3 so that it will not bounce erratically isdifficult. It is possible to throw toy 30 so that it will make athree-point landing with the distal end of each leg 31 to 33 hitting theground simultaneously or almost simultaneously so that toy 30 hits theground and stops dead. Such a three-point landing is highly unlikely.

As used herein, a toy has an erratic bounce when, after it hits theground, it moves in a direction different from the direction it wastraveling just prior to hitting the ground.

One important reason why toys with an erratic bounce are critical in thepractice of the invention is that when a toy makes an erratic bounce thespeed of travel of the toy after the bounce appears less, sometimessignificantly less, than if the toy continues in the same direction oftravel after the toy bounces. Since a primary object of the invention isto minimize the risk of injury to an animal, it is imperative that a toynot continue going in the same direction like a freight train after ithits the ground, but that some of the inertia of the toy be consumed byinsuring that the toy bounce erratically. The ability of the toy to becompressed and to be bent on contacting the ground also consumes some ofthe toy's inertia.

An improved method for producing an animal toy is depicted in FIG. 5.The method includes the step 50 of “mold top half and bottom half oftoy”. If desired, methods other than molding can be utilized in step 50to form the top and bottom halves of a toy.

Step 51 comprises “apply glue along seam edge of each half, press halvestogether along seam edges to form unitary member having a seam line,place halves in mold to heat and cure adhesive”. Fasteners or methodsother than gluing can be utilized to fasten together the top and bottomhalves along a seam line.

Step 52 comprises “apply rubber tape along seam line”. The tape canconsist of any polymer or other material which is softened (by heatingor any other desired method) and then hardens and cures.

Step 53 comprises “apply upper felt cover to top half of unitary membersuch that edge of felt cover overlaps rubber tape”.

Step 54 comprises “apply lower felt cover to bottom half of unitarymember such that edge of lower cover overlaps rubber tape and opposesedge of upper felt cover”.

Step 55 comprises “place unitary member in mold to soften and curerubber tape and to draw opposing edges of felt covers together”.

Additional features of the invention, along with the method of FIG. 5,are further illustrated in FIGS. 6 to 9. The toy illustrated in FIGS. 6to 9 has the shape of a dog bone, but the shape and dimension of toysmade in accordance with the invention can vary as desired.

Symmetrical hollow opposing halves 60 and 61 are illustrated in FIG. 6.Each half 60 and 61 is presently preferably molded from a rubber orpolymer compound which, after being molded and cooled to ambienttemperature (76 degrees F.) is bendable and resilient. The material andmethod utilized to manufacture each half can vary as desired.

Halve 60 includes generally flat upper area 64, front side 75, back side74, inner surface 72, and edge 65. Arcuate edge 67 extends around halve60. Halve 61 includes generally flat lower area 71, front side 76, backside 73, inner surface 63, and edge 62. Arcuate edge 70 extends aroundhalve 61. Edge 62 opposes and has a shape, contour and dimensionequivalent to the shape and dimension of edge 65.

Line of weakening or groove 85 extends along the inside of arcuate edge67. Line of weakening or groove 86 extends along the inside of arcuateedge 70. Lines of weakening 85, 86 are important in the practice of oneembodiment of the invention because they function to require lesspressure be applied to deform edges 67 and 70, respectively, (and thefelt covering edges 67 and 70) inwardly or outwardly. When less force orpressure is required to deform edges 67 and 70, it is less likely thatedges 67 and 70 will cause injury when a toy constructed in accordancewith the invention strikes an animal or human being. The lines ofweakening can be formed in any desired manner. For example, instead ofgrooves 85, 86, perforations can be formed through edges 67 and 70 toremove material from and weaken edges 67 and 70. The lines of weakeningcan be formed on the inside of arcuate edges 67 and 70, on the outsideof arcuate edges 67 and 70, through edges 67 and 70, etc.

The radius of curvature 66 of edges 67 and 70 can vary as desired. Theradius of curvature of the edges of a toy which are on the outer surfaceof a toy and can contact the body of an animal or human being is,however, preferably ¾ of an inch or greater. A larger radius ofcurvature makes it less likely that an edge 67, 70 will penetrate andinjure an eye or other part of the body of an animal or human being.

FIG. 7 also illustrates the top 60 and bottom 61 halves. In addition,dashed lines 77 in FIG. 7 illustrate adhesive which is placed on edge62, and if desired on edge 65, to glue together halves 60 and 61 to formthe seam line 79 illustrated in FIG. 8. After halves 60 and 61 are gluedor otherwise fastened together, a strip of polymer or rubber is wrappedaround and covers seam line 79. The polymer strip is indicated by dashedline 78 in FIG. 8. The polymer strip 78 can be sticky and adhere byitself to tops 60 and 61. Or, adhesive can be utilized to adhere strip78 to tops 60 and 61. Or, some of the adhesive used to adhere the halves60 and 61 may ooze out from seam line 79 and be used to adhere strip 78to halves 60 and 61 over seam line 79. If desired, polymer strip 78 canbe omitted.

Once strip 78 is fastened over seam line 79, a felt cover, indicated bydashed line 80 in FIG. 8 is placed over halve 60 such that edge 82overlaps strip 78. A felt cover, indicated by dashed line 81 in FIG. 8is placed over halve 61 such that edge 83 overlaps strip 78. Edges 82and 83 are spaced apart as shown in FIG. 8. An adhesive (not shown) canbe applied to covers 80, 81 or to halves 60, 61 to facilitate theadhering of the covers 80, 81 to the halves 60, 61.

Once the strip 78 and covers 80 and 81 are applied, the halves 60 and 61are placed in a mold 88, 89. One or more mold parts 88 and 89 are movedto compress halves 60, 61 and covers 80, 81 in the directions indicatedby arrows 100 and 101. Mold edges 92 to 95 engage edges 82 and 83 tostretch edges 82 and 83 toward one another in the directions indicatedby arrows 96 and 97 in FIG. 9. Mold 88, 89 heats, softens, and cures thepolymer or rubber in strip 78. Mold edges 92 to 95 also compress edges82, 83 inwardly against strip 78 to facilitate the adhering of edges 92and 95 to strip 78 when strip 78 softens. The mold 88, 89 also heatsfelt covers 80 and 81 to facilitate adherence of the covers 80 and 81 tohalves 60 and 61. If strip 78 is omitted, mold edges 88, 89 compressopposing edges 82, 83 toward each other, preferably so the opposingedges abut.

Another method for applying rubber or polymer, either in place of or inconjunction with strip 78, is to prepare a stack of felt covers 80and/or 81. The number of covers in the stack(s) can vary as desired, butpresently there are about fifty covers in a stack. The edges of thecovers in each stack collectively form the sides of the stack. Latex oranother synthetic or natural rubber or polymer mixture is slathered orbrushed onto the sides of the stack, i.e. is applied to the edges of thecovers in the stack. The viscosity of the latex or other polymer mixturecan vary as desired, but the mixture presently has a viscosity similarto that of honey. Covers 80 and 81 are peeled off each stack and appliedto halves 60, 61. The mold edges 92 to 95 engage the edges 82 and 83 tostretch edges 82 and 83 toward one another in the directions indicatedby arrows 96 and 97 in FIG. 9. Mold 88, 89 heats and cures the polymeror rubber that was applied to the edges of covers 80 and 81 while thecovers were in a stack(s). Mold edges 92 to 95 compress edges 82, 83inwardly toward one another. The polymer or rubber that was slathered onthe edges 82, 83 functions to hold and seal edges 82, 83 adjacent oneanother.

The thickness, indicated by arrows T1, of the wall of halves 60 and 61with respect to the thickness, indicated by arrows T2, of the feltcovers 80, 81 is important in one embodiment of the invention. Many dogtoys utilize heavy, thick, relatively hard rubber, probably with theintent of making it difficult for a dog to chew up the toy. Such rubbercan, however, turn the toy into a dangerous projectile when the toy isthrown. I have discovered that utilizing a felt cover with a thicknessin the range of 1.0 millimeter to 8.0 millimeters, preferably to 2.0 mm.To 6.0 mm., in combination with a resilient, pliable rubber or polymermaterial having a thickness in the range of only 1.0 to 8.0 mm,preferably 2.0 mm to 6.0 mm, produces a laminate having good “chewresistance” and having the additional feature of being quite safebecause the thin, resilient polymer material is readily deformed and isnot hard and because the thick felt tends to dissipate the forcesproduced when a dog or other animal bites the toy. Accordingly, theratio of the thickness of the felt covers 80, 81 to the thickness ofpolymer material comprising halves 60 and 61 is in the range of 1:6 to1:0.15, preferably 1:3 to 1:0.5.

FIGS. 10 to 12 illustrate another embodiment of the toy of the inventiongenerally indicated by reference character 200 and including a hollowcylindrical core 211 fabricated from pliable elastic rubber, fromanother elastomer, or from any other desired material. Pieces 212, 213of felt or another desired material can, if desired, be adhesivelysecured or otherwise affixed to the outer cylindrical surface 228 ofcore 211. Fabric pieces 212, 213 are shaped and dimensioned and appliedto surface 228 such that a space or groove of substantially constantwidth between the pieces 212, 213 is formed. This groove is filled withan elastic rubber material to form strip 214. Alternately, one or morefabric pieces can be utilized to completely cover surface 228, afterwhich a strip 214 of material can be attached on or in the fabric toform a strip 214 dividing the fabric into sections on either side of thestrip 214. Strip 214 presently has a width in the range of one-sixteenthto seven-sixteenths of an inch, preferably two-sixteenths tofive-sixteenths of an inch. The width of strip 214 can vary as desired.

Cylindrical end piece 218 includes member 219 made from rubber oranother elastomer or other desired material and includes a fabric piece220 adhesively secured or otherwise secured to piece 219. Piece 218includes inner circular surface 206. Cylindrical aperture 217 is formedthrough piece 218. Piece 218 is secured to the end 205 of core 11 and/orto the end 222 of fabric pieces 212, 213. Instead of utilizing piece218, each half 300 of core 211 can include a semi-circular end 238comparable to end 237 FIG. 12), except that a semi-circular opening 239is be formed through end 238 so that when the upper and lower halves ofcore 211 are glued together to form core 211, an opening comparable toopening 217 is formed through ends 238.

Rope 230 includes distal end 234, proximate end 235, and an intermediateportion 236 extending between the distal and proximate ends 234, 235. Ananchor 231 is formed at distal end 234. The anchor 231 can be formed bytying end 234 into the knot 231 shown, by tying end 234 around a rod, byaffixing a glass ball to end 234, etc. Any method or apparatus can beutilized to form an anchor at distal end 234 as long as the anchor isshaped and dimensioned such that it can not fit or be pulled throughaperture 217.

FIG. 11 illustrates toy 200 fully assembled.

FIG. 12 illustrates the lower semi-cylindrical half 300 of core 211,which includes edge surface 204 and edge surface 233. The upper half ofcore 211 presently has a shape and dimension equivalent to the lowerhalf of core 211. When the two semi-cylindrical halves of core 211 areglued together along their edge surfaces 204, the hollow cylindricalcore 211 illustrated in FIG. 10 results. When the two semi-cylindricalhalves of core 11 are glued together along edges 233, circular diaphragm232 (FIG. 10) results.

Diaphragm 232 divides the inner area of toy 200 into two compartments229 and 229A. Compartment 229A is fully sealed and enclosed by diaphragm232 and a portion of core 211. Compartment 229 is not sealed because ofaperture 217, however, compartment 229 is circumscribed and enclosed byanother portion of core 211.

Toy 200 can be manufactured in any desired manner, however, it ispresently preferred that knot 231 (or some other anchor) be positionedin compartment 229 when the upper and lower halves of core 211 are gluedtogether along edges 204, 233 (or are otherwise affixed to one another)to form hollow cylindrical core 211. After core 211 is formed to producesealed compartments 229 and 229A, compartment 229A is filled with air orsome other desired gas or liquid and compartment 229 is filled with airand anchor 231. The intermediate portion 236 of rope 230 extends fromanchor 231, out through aperture 217, and to proximate end 235. Felt orfabric layers 212, 213 are then applied and secured to outer surface 228in the manner earlier described. Or, if desired, a felt layer 212, 213need not be applied to core 211.

When layers 212, 213 are applied to core 211, the portion of rope 230extending outwardly from aperture 217 is usually temporarily folded intoa compact configuration and secured in that configuration with a rubberband, string, etc. The folding of a portion of rope 230 into a compactconfiguration facilitates the application of felt layers 212, 213 andfacilitates transport of core 211 through the remainder of themanufacturing process.

In use of the toy 200 depicted in FIG. 11, the portion of rope 230extending outwardly from aperture 217 is manually grasped and used tothrow the toy away from the user so a dog or other animal can retrievethe toy 200 and bring toy 200 back to the user. Toy 200 can also beutilized as a toy for young or adult human beings. Toy 200 need not bethrown but can be given to a dog to play with, can be used by letting adog grasp the felt covered body of the toy in its mouth to pull on thebody while the train pulls on rope 230, etc.

A manufacturing process for toy 200 is set forth in FIG. 13 and includesthe step 250 of molding the top half and bottom half of the toy with adiaphragm formed intermediate the ends of each half so that thediaphragm 232 divides the inner hollow area into two compartments, onecompartment 229A to be sealed when the top and bottom 300semi-cylindrical halves are joined, and the other compartment 229 not tobe sealed when the bottom halves are joined.

In step 251, an anchor is formed at the distal end 234 of rope 230. Thisis followed by step 252 in which the proximate end 235 is extendedthrough opening 217 (or 239) so that anchor 231 is positioned in theunsealed compartment 229 of toy 200. In step 253, glue is applied alongthe seam edges 204, 233 of each half, the halves are pressed togetheralong the seam edges to form core 211 having a seam line defined byedges 204 and, to form sealed compartment 229A and unsealed compartment229 containing anchor 231. The member is then, in step 254, placed in amold to heat and cure the adhesive that extends along seam edges 204,233. Felt, another fabric, or another material can then, if desired beapplied to outer surface 228 of core 211.

In FIG. 10, one end of rope 230 is in compartment 229. If desired, apair of apertures 242, 243 can be formed through piece 218 and/or in thecylindrical wall circumscribing compartment 229. The apertures are sizedare positioned to permit an end of rope 230 to be threaded throughaperture 243 into compartment 229, through compartment 229, and throughaperture 242 to a location outside of compartment 229 and surface 228.In this fashion, rope 230 extends completely through compartment 229 andboth ends of rope 230 are located outside compartment 229. Knots orother anchor means can be formed in the ends of the rope such that theends of the rope cannot be pulled through apertures 242, 243 intocompartment 229. As used herein, the term rope refers to a length ofpliable material. The pliable material can be woven, extruded (likepliable plastic line), or otherwise formed. Conventional woven cotton ornylon rope is, however, presently preferred in the practice of theinvention. Rope 230 can have a conventional cylindrical shape like thatshown in the drawings, can be substantially flat (if a leather strap isused), or can take on any desired shape and dimension.

Compartment 229 is, as noted, presently preferably filled with air.Sand, rubber, foam, or any other desired material can completely orpartially fill compartment 229. Compartment 229 is presently preferablynot sealed. If desired, compartment 229 can be sealed and filled withany desired solid, liquid, gas or combination thereof. Compartment 229can be filled with any desired solid, liquid, gas or combinationthereof.

As used herein, the term fabric includes material made by weaving,felting, knitting, knotting, bonding, or crocheting natural or syntheticfibers and/or filaments. Examples of natural fibers are, withoutlimitation, cotton, wool, and silver. Examples of synthetic fibers are,without limitation, nylon, rayon and Kevlar (™). Felts are, are earliernoted, presently preferred in the practice of the invention.

Another embodiment of the invention is illustrated FIG. 14 and isgenerally indicated by reference character 301. Cylindrical toy 301comprises a compressibly elastically deformable hollow thin walledelastomer core 310 (FIG. 25) that circumscribes and encloses a selectedcompressible gaseous volume 330. Gaseous volume 330 typically comprisesair. Toy 301 includes center 321 that is equidistant from the circulartop (not visible) and circular bottom 311 of toy 301. The circular topis equivalent in size to bottom 311 and is parallel to and spaced apartfrom bottom 311. Cylindrical outer wall 312 extends between andinterconnects the circular top and bottom 311. Points on the outer andinner surfaces of wall 312 are at varying distances from center 321.Wall 312, the circular top, and circular bottom 311 can have any desiredthickness but preferably each are less than about eight millimetersthick.

A fabric cover is affixed to the outer surface of core 310 and has aselected thickness. The ratio of the thickness of the fabric cover tothe thickness of the wall 312 is in the range of 1:6 to 1:0.15. Theratio of the thickness of the fabric cover to the thickness of thecircular top or circular bottom 311 is in the range of 1:6 to 1:0.15. Atleast one elongate strip of material can, if desired, extend over theouter surface of the core as a line of demarcation to separate thefabric cover into at least two areas, one on either side of the strip ofmaterial. This line of demarcation is not shown in FIG. 14 but could, byway of example and not limitation, be comparable to the line ofdemarcation 14 illustrated in FIG. 1.

At least one aperture 308 (FIGS. 24 and 25) is formed in core 310. Anaperture 305 can also, if desired, be formed through the fabric cover.The fabric cover includes a circular portion 303 covering the circulartop of core 310, includes a circular portion 304 covering the bottom 311of the core 310, and includes a cylindrical portion or wall 302 coveringthe cylindrical wall 312 of core 310. Wall 302 extends between andinterconnects portions 303 and 304. A hollow sound device 307 isinserted in aperture 308. Device 307 produces a sound audible to ananimal. As used herein, a sound audible to an animal is defined as asound in the range of frequencies that is audible to a dog because asound in this range of frequencies can in most cases be heard by humanbeings and many other animals. The sound device 307 illustrated in FIG.16 is presently preferred in the practice of the invention, but thesound device 330 illustrated in FIG. 15 can be utilized, as can be anyother desired sound device.

Sound device 307 includes hollow cylindrical leg 338 and upstanding lipor rim 337 that is connected to and extends outwardly from leg 338.Apertures 331 and 332 are formed in the top of and extend downwardlyinto leg 338. As is illustrated in FIG. 17, a semi-circular, hollow,tapered toe 341 is provided with a reed or a thin piece of plastic 342that extends downwardly over and slightly spaced apart from the openingin toe 341. When air travels upwardly into toe 341 in the direction ofarrow 335, the air also passes by reed 342 and causes reed 342 tovibrate. Reed 342 or the movement of reed 342 in conjunction with theproximity of toe 341 produces sound, typically a sound with a highpitch. The construction of a wide variety of sound devices is well knownin the art, as are a variety of sounds that such devices can produce andthat have a high, low, or intermediate pitch. Any desired sound devicecan be utilized in the practice of the invention. Device 307 producessound only when air flows through device 307 at a selected rate of flow.If the rate of flow of air through device 307 is too slow, device 307will not produce sound. It is desirable in the practice of the inventionthat device 307 produce sound when the top and bottom 311 of toy 301 arecompressed rapidly by a dog holding toy 301 in its mouth. The rate offlow of air through device 307 required to cause device 307 to producesound can be varied as desired. Air flowing upwardly in the direction ofarrow 335 in FIG. 17 flows past reed 342, into toe 341 in the mannerindicated by arrow 340, and out through the apertures 331, 332 formed inthe top of device 307. Air flowing out through apertures 331, 332travels in the directions indicated by arrows 333 and 334.

The hollow sound device 330 illustrated in FIG. 15 operates in the samemanner as device 307. Air passing upwardly into device 330 travels overa reed (not shown) and into a toe (not shown) and out through aperture352 in the direction of arrow 351. Device 330 includes conical leg 353having a top including circular edge 354. Conical leg 353 is sized suchthat it can be forced downwardly through an aperture 308 to distend theelastic material around aperture 308 to permit leg 353 to be pushedthrough aperture 308 and into the interior of a toy 301. The diameter ofedge 354 is, however, significantly greater than the diameter of opening308 such that once leg 353 is forced through aperture 308 into theinterior of toy 301, leg 353 can not be readily pulled back out throughaperture 308.

One method for making a toy 301 is illustrated in FIGS. 18 to 21. InFIG. 18 a compressibly elastically deformable hollow thin-walledelastomer core 410 is provided. The core 410 circumscribes acompressible gaseous volume 430, which volume typically is air. The coreincludes a center 421. Center 421 is equidistant from the circular top(not visible) and circular bottom 411 of core 410. The circular top isequivalent in size to bottom 411 and is parallel to and spaced apartfrom bottom 411. Cylindrical outer wall 412 extends between andinterconnects the circular top and circular bottom 411. Points on theouter and inner surfaces of wall 412 are at varying distances fromcenter 421. Wall 412, the circular top, and the circular bottom 411 canhave any desired thickness but preferably are less than about eightmillimeters thick. At least one aperture 408 is formed in core 410.

As is illustrated in FIG. 19, a removable plug 406 is fixedly insertedin aperture 408. Insertion of the plug is important in the practice ofthe method of the invention because when a fabric cover is affixed tothe outer surface of core 410, pressure and heat are used. If the plug406 is not utilized and is not permitted to function to maintain airinside core 410 when the pressure is applied, the core 410 can collapse,ruining the attempt to apply the fabric cover.

After the plug 406 is inserted, a fabric cover is affixed to the outersurface of core 410 using pressure and a material that causes the fabriccover to adhere to the core 410. The fabric cover has a selectedthickness. The ratio of the thickness of the fabric cover to thethickness of the wall 412 is in the range of 1:6 to 1:0.15. The ratio ofthe thickness of the fabric cover to the thickness of the circular topor circular bottom 311 is in the range of 1:6 to 1:0.15. At least oneelongate strip of material can, if desired, also be applied to andextend over the outer surface of the core as a line of demarcation toseparate the fabric cover into at least two areas, one on either side ofthe strip of material. This line of demarcation is not shown in FIG. 14but could, by way of example and not limitation, be comparable to theline of demarcation 14 illustrated in FIG. 1. Methods for applying thefabric cover and lines of demarcation are described earlier herein. Anydesired method can be utilized to apply the fabric cover and lines ofdemarcation. The material comprising the fabric cover can vary asdesired, but presently preferred materials are also described earlierherein. An aperture 405 can also, if desired, be formed through thefabric cover. The fabric cover includes an upper circular portion (notshown) covering the outer surface of the circular top of core 410,includes a lower circular portion (not shown) covering the outer surfaceof the bottom 411 of the core 410, and includes a cylindrical portion orwall 402 extending around and covering the cylindrical wall 412 of core410. Wall 402 interconnects the upper and lower circular portions of thefabric cover.

After the fabric cover is applied, plug 406 is removed and sound device307 is inserted in aperture 408 in the manner shown in FIG. 21. Rib 337of device 307 compresses and indents a portion of the cylindrical sideof aperture 408 and functions to anchor device 307 in aperture 408. Ashown in FIG. 14, it is preferred that a cylindrical piece of fabricmaterial or “plug” 306 is used to cover the top of sound device 307 suchthat animal toy 307 appears to be completely covered by fabric material.Piece 306 can also comprise a flap that is partially attached to andfolded back onto the fabric cover such that piece 306 can be fold offthe fabric cover onto the top of device 307. Piece 306 or some other wayof concealing the top of device 307 is important because a dog canattempt to remove the sound device 307 from core 410. If the location ofthe sound device 307 is covered or disguised, it makes it more difficultfor a dog to find and remove or damage device 307.

It is preferred that core 410 include an area 413 that is thicker thanthe top, bottom 411, or wall 412 of core 410. The increased volume orsize of area 413 functions to protect sound device 307 and make it moredifficult for an animal to remove device 307 from core 410.

Another method for making a toy 301 is illustrated in FIGS. 22 to 25. InFIG. 22 a compressibly elastically deformable hollow thin-walledelastomer core 310 is provided. The core 310 completely sealinglycircumscribes a compressible gaseous volume 330, which volume typicallyis air. The core includes a center 321. Center 321 is equidistant fromand generally centered with respect to the circular top (not visible)and circular bottom 311 of core 310. The circular top is equivalent insize to bottom 311 and is parallel to and spaced apart from bottom 311.Cylindrical outer wall 312 extends between and interconnects thecircular top and circular bottom 311. Points on the outer and innersurfaces of wall 312 are at varying distances from center 321. Wall 312,the circular top, and circular bottom 311 (or wall 412, wall 512, bottom411, bottom 511, etc.) can have any desired thickness including any ofthe wall thicknesses previously discussed herein for other embodimentsof the invention, but presently preferably are less than about eightmillimeters thick. Core 310 includes a portion 313 that is formed inwall 312 and that has greater thickness and mass than the remainder ofwall 312. Portion 313 functions, as will be seen, to provide support fora sound device 307 that is subsequently inserted in core 310. Anotherimportant function of portion 313 is to made core asymmetric. Suchasymmetry promotes the erratic bouncing of toy 301 because a portion ofthe weight of the toy is not equally distributed about the wall 312.Since toy 301 can take on any desired shape and dimension, the asymmetrycaused by portion 313 is important because it causes erratic bouncing oftoy 301 even when toy 301 is spherical. If desired, portion 313 can beomitted, i.e., wall 312 can have a constant thickness throughout.Omitting portion 313 reduces the likelihood that toy 301 will bounceerratically, particularly if toy 301 is spherical. In addition, even ifportion 313 is not utilized and wall 312 has the same thickness at allpoints, simply forming hole 308 in wall 312 and inserting device 307tends to make toy 301 asymmetric because the device 307 ordinarily doesnot have the same mass as the material in wall 312. An aperture 308 can,if desired, be formed in the top or bottom 311 of core 310 or at anydesired location in core 310. Since, as noted, one function of portion313 is to promote asymmetry due to the increased weight or mass thatportion 313 adds to a portion of core 310. As would be appreciated bythose of skill in the art, portion 313 can be located at any desiredlocation on or in core 310. The shape and dimension of portion 313 canvary as desired. Two or more portions 313, each having the same ordifferent shape and dimension, can be formed on or in core 310. Aportion 313 can, if desired, not be attached to the wall of core 310 inthe manner of portion 313, but can be inside core 310 and be free tomove around therein. The thickness of the wall of core 310 can be variedas desired to promote either an erratic bounce or a uniform bounce of atoy 301 along a straight line.

A fabric cover is affixed to the outer surface of core 310 usingpressure and a material that causes the fabric cover to adhere to thecore 310. Core 310 can, because core 310 completely sealinglycircumscribes the gaseous volume 330, withstand the pressure thatordinarily must be applied in order to affix the fabric cover to thecore 310. Consequently, core 310 does not collapse when the pressure isapplied. FIG. 23 illustrates the fabric cover applied to core 310. Thefabric cover has a selected thickness. The ratio of the thickness of thefabric cover to the thickness of the wall 312 is in the range of 1:6 to1:0.15. The ratio of the thickness of the fabric cover to the thicknessof the circular top or circular bottom 311 is in the range of 1:6 to1:0.15. At least one elongate strip of material can, if desired, also beapplied to and extend over the outer surface of the core as a line ofdemarcation to separate the fabric cover into at least two areas, one oneither side of the strip of material. This line of demarcation is notshown in FIG. 14 but could, by way of example and not limitation, becomparable to the line of demarcation 14 illustrated in FIG. 1. Methodsfor applying the fabric cover and lines of demarcation are describedearlier herein. Any desired method can be utilized to apply the fabriccover and lines of demarcation. The material comprising the fabric covercan vary as desired, but presently preferred materials are alsodescribed earlier herein. The fabric cover includes an upper circularportion 303 (FIG. 14) covering the outer surface of the circular top ofcore 310, includes a lower circular portion 304 (FIG. 14) covering theouter surface of the circular bottom 311 of the core 310, and includes acylindrical portion or wall 302 extending around and covering thecylindrical wall 312 of core 310. Wall 302 interconnects the upper 303and lower 304 circular portions of the fabric cover.

After the fabric cover is applied, an aperture 308 is drilled orotherwise formed in core 310. Aperture 308 includes a countersunkportion that receives the top or head 400 of device 307 so that the top400 of device 307 is flush with or inset with respect to the outersurface of core 310. An aperture 305 is also formed through the fabriccover. The aperture 308 can be formed at this point in the processbecause fabric cover 302 has been applied, and the air inside core 310is no longer required to function to prevent the collapse of core 310when pressure is applied to the outside of core 310. FIG. 24 illustratescore 310 and the fabric cover after apertures 308 and 305 are formed.

Sound device 307 is inserted in aperture 308 in the manner shown in FIG.25. Rib 337 of device 307 compresses and indents a portion of thecylindrical side of aperture 308 and functions to anchor device 307 inaperture 308. Any desired method or apparatus can be utilized to fixdevice 307 in aperture 308 or in core 310. As shown in FIG. 14, it ispreferred that a cylindrical piece of fabric material or “plug” is usedto cover the top of sound device 307 such that animal toy 301 appears tobe completely covered by fabric material. This is important because adog or other animal can attempt to remove the sound device 307 from core310. If the location of the sound device 307 is covered or disguised, itmakes it more difficult to a dog to find and remove or damage device307.

In use of the toy 301 (or 401 or 501), the toy is given to a dog orother animal, or is thrown so that the dog has to retrieve the toy. Whenthe dog compresses the toy 301 in its mouth, it compresses air incompressible volume 330, forcing air outwardly through device 307 in themanner indicated by arrows 335, 340, 333, and 334 in FIGS. 16 and 17.This causes device 307 to produce a sound that the dog hears. When thedog releases the compressive pressure on toy 301, the toy elasticallyreturns to the normal configuration illustrated in FIG. 14. When the toyelastically returns to the normal configuration illustrated in FIG. 14,air is drawn through device 307 back into volume 330 in directionsopposite the directions indicated by arrows 333, 334, 340, and 335. Whenair is drawn back into volume 330, device 307 also produces sound thatthe dog can hear. If desired, however, device 307 need only producesound when air travels through device 307 in one direction-either whenair is expelled from volume 330 through device 307 or when is air drawnthrough device 307 into volume 330. One particular advantage of toy 301is that device 307 makes the toy safer to use. When it is dusk or darkand it is difficult for an animal to see the toy, sound made by the toyhelps the animal locate the toy. Similarly, when the animal is in highgrass and has difficulty seeing toy 301, any sound made by the toy 301helps the animal locate the toy. Since toy 301 is compressible, the toywill typically, although not necessarily, generate noise when the toystrikes the ground or an object and is compressed. When the toy iscompressed, air is forced outwardly through device 307, producing soundaudible to the animal.

Still another method for making a toy 301 is illustrated in FIGS. 26 to28. In FIG. 26 a compressibly elastically deformable hollow thin-walledelastomer core 510 is provided with a fabric cover affixed to the outersurface of core 510. The core 510 completely sealingly circumscribes acompressible gaseous volume 530, which volume typically is air, butwhich can consist of any other gas or gasses or fluid or fluids. Thecore includes a center 521. Center 521 is equidistant from the circulartop (not visible) and circular bottom 511 of core 510. The circular topis equivalent in size to bottom 511 and is parallel to and spaced apartfrom bottom 511. Cylindrical wall 512 extends between and interconnectsthe circular top and circular bottom 511. Points on the outer and innersurfaces of wall 512 are at varying distances from center 521. Wall 512,the circular top, and the circular bottom 511 can have any desiredthickness, but preferably are less than about eight millimeters thick.Toy 501 can take on any desired shape and dimension.

The ratio of the thickness of the fabric cover to the thickness of thewall 512 is in the range of 1:6 to 1:0.15. The ratio of the thickness ofthe fabric cover to the thickness of the circular top or circular bottom511 is in the range of 1:6 to 1:0.15. At least one elongate strip ofmaterial can, if desired, also be applied to and extend over the outersurface of the core as a line of demarcation to separate the fabriccover into at least two areas, one on either side of the strip ofmaterial. This line of demarcation is not shown in FIG. 14 but could, byway of example and not limitation, be comparable to the line ofdemarcation 14 illustrated in FIG. 1. The material comprising the fabriccover can vary as desired, but presently preferred materials are alsodescribed earlier herein. The fabric cover includes an upper circularportion (not shown) covering the outer surface of the circular top ofcore 510, includes a lower circular portion (not shown) covering theouter surface of the bottom 511 of the core 510, and includes acylindrical portion or wall 502 extending around and covering thecylindrical wall 512 of core 510. Wall 502 interconnects the upper andlower circular portions of the fabric cover.

An aperture 508 is drilled or otherwise formed in core 510. An aperture505 is also formed through the fabric cover. Apertures 505 and 508 areillustrated in FIG. 27. The aperture 508 can be formed at this point inthe process because fabric wall 502 has been applied, and the air insidecore 510 is no longer required to function to prevent the collapse ofcore 510 when pressure is applied to the outside of core 510.

Sound device 307 is inserted in aperture 508 in the manner shown in FIG.28. Rib 337 of device 307 compresses and indents a portion of thecylindrical side of aperture 508 and functions to anchor device 307 inaperture 508. Any desired method or apparatus can be utilized to fixdevice 307 in aperture 508 or in core 510. As shown in FIG. 14, it ispreferred that a cylindrical piece of fabric material or “plug” is usedto cover the top of sound device 307 such that animal toy 501 appears tobe completely covered by fabric material. This is important because adog or other animal can attempt to remove the sound device 307 from core510. If the location of the sound device 307 is covered or disguised, itmakes it more difficult to a dog to find and remove or damage device307.

Still another embodiment of the toy includes a rib that is formed insideof core 510 and that is indicated in FIG. 27 by dashed lines 520. Sounddevice 307 is mounted in rib 520 such that compressing toy 501 causingair to move through device 307 from one side of rib 520 to the otherside of rib 520 such that device 307 produces a sound that can be heardby a dog or other animal. While it is possible that this embodiment ofthe invention will function to produce sound even if an aperture 508 isnot formed through core 510, it is preferred that an aperture 508 beformed in core 510 to facilitate the ready travel of air through device307. Installing device 307 in rib 520 makes it much more difficult for adog to damage device 307. The dog would have to tear open core 510 toaccess device 307. Rib 520 and device 307 preferably completely dividethe inner volume 530 into two separate compartments.

In still another embodiment of the invention, the process set forth inFIGS. 18 to 21 is utilized, except that in FIG. 19 device 307 isinstalled instead of plug 406, and a plug is installed directly indevice 307 to prevent air from escaping from volume 430 while the fabriccover is applied. After the fabric cover is applied, the plug blockingdevice 307 is removed to permit air to flow through device 307 when thetoy 401 is compressed.

The soft fabric cover described herein on the toys of the invention is,as noted, important because it reduces the risk of injury to an animal.The processes set forth in FIGS. 18 to 25 are central to the inventionbecause they enable application of the fabric cover to be achieved underpressure and still allow a sound device to be installed and concealed ina toy.

Another embodiment of the invention comprises molding or otherwiseforming an opening 331 (FIG. 22) in the core 310 when core 310, or aportion of core 310, is being produced. The opening 331 is shaped anddimensioned such that when air travels through the opening 331 (eithertraveling from the inside of core 310 out through opening 331 orvice-versa) at a selected flow rate audible sound is produced that canbe heard by a dog or other animal. The advantage of forming opening 331during the molding of core 310 is that the resulting animal toy 301 doesnot require the drilling or other formation of an aperture 308 in core310 and does not require the subsequent insertion of a separate sounddevice 307 in aperture 308. Sound device 307 and aperture 308 are notrequired because the opening 331 functions to produce sound when airpasses therethrough. In a similar manner, the aperture 508 formed incore 510 in FIG. 27 can be shaped and dimensioned to produce sound whenair travels into or out of core 510 at a desired flow rate. Whenaperture 508 is so formed, it is not necessary to insert device 307 inaperture 508 to produce sound. Aperture 331 and aperture 508 (whenaperture 508 is formed to produce sound when air passes therethrough)demonstrate embodiments of the invention in which separate sound devices307 need not be inserted in a toy 301, 501.

One or more bulkheads can be formed inside a core 310, 410, 510 of a toy301, 401, 501. The bulkheads can extend partially or completely acrossthe volume inside the core. A bulkhead can include an aperture formedtherein to produce noise when air passes therethrough, and can include asound device 307 inserted in the bulkhead to produce noise when airpasses through the sound device 307.

The outer surface of a sound device 307 can—in addition to or in placeof a rib 337 that alters the shape of an opening 308, 408, 508—be madeof a material that frictionally engages the material comprising the wallof the opening 308, 408, 508 that contacts the outer surface of device307. This makes it more difficult for an animal to remove device 307from an opening 308, 408, 508. In this respect, soft polymers tend toadhere frictionally to one another more effectively that hard smoothpolymers. Or, a soft polymer with a high coefficient of friction canfunction to adhere to the surface of a hard smooth polymer or othermaterial.

Another method for making a toy of the general type illustrated in FIGS.18 to 28 is illustrated in FIG. 29. In step 340, a compressiblyelastically deformable spherical hollow thin-walled rubber (or otherelastomer) core is provided. The core includes an aperture shaped anddimensioned to receive a squeaker. The aperture can be formed in anydesired manner, including by drilling or by being formed when the core(or a part of the core) is formed in a mold. The shape and dimension ofthe core can vary as desired and need not be spherical. While notnecessary, the aperture preferably includes an inset or countersunkportion similar to the inset portion 509 illustrated in FIG. 27. The capor top 400 of the squeaker 307 seats in such inset portion so that thetop 400 of the squeaker 307 is flush with the outer surface of the core.

In step 341, adhesive is applied to the exterior of the rubber core,after which a layer of felt is applied in step 342. Thecore-adhesive-felt combination is heated in step 343, after which anopening is formed in the felt in step 344. The opening is inregistration with the aperture formed in the core. The opening is madeby cutting through the felt and removing felt from about the aperture. Asqueaker 307 is inserted in the opening in the core in step 345. In step346, a piece of felt is glued over the top 400 of the squeaker 307 todisguise the location of the squeaker. A iron or other instrument isused in step 347 to flatten and smooth the piece of felt.

The ability to produce an animal toy according to the method set forthin FIG. 29 was a surprising result because it had been suggested thatattempting to apply felt to a rubber core when there was an aperture inthe core would cause the core to collapse. When the core has a wallthickness in the range set forth earlier herein, the core appears toretain its shape and not to collapse when felt is applied and the coreand felt (and adhesive) are compressed and heated in a mold. If unduecompressive pressure is applied to the core-adhesive-felt, the corelikely will collapse. Only minimal experimentation is normally requiredto determine a reasonable compressive pressure that will not cause thecore-adhesive-felt to collapse when heated to about 135 degrees C. to145 degrees C. for five minutes. It may be possible to apply no or onlyminimal compressive force to the felt and core when the mold contactsthe felt because heat alone will cure or otherwise affect the adhesivesuch that the felt or other fabric properly adheres to the core. Whilethe elevated temperature utilized to heat the mold—and therefore thefelt and adhesive—is presently 135 degrees C. to 145 C., any desiredelevated temperature in excess of the ambient room temperature of about76 degrees F., preferably in excess of 100 degrees F., most preferablyin excess of 200 degrees F., can be utilized to heat the felt andadhesive.

A further method for producing an animal toy of the general typeillustrated in FIGS. 18 to 28 is illustrated in FIG. 30. In step 350, acompressibly elastically deformable spherical hollow thin-walled rubber(or other elastomer) core is provided. The core includes an apertureshaped and dimensioned to receive a squeaker. The aperture can be formedin any desired manner, including by drilling or by being formed when thecore (or a part of the core) is formed in a mold. The shape anddimension of the core can vary as desired and need not be spherical.While not necessary, the aperture preferably includes an inset orcountersunk portion similar to the inset portion 509 illustrated in FIG.27. The cap or top 400 of the squeaker seats in such inset portion sothat the top 400 of the squeaker 307 is flush with or recessed from theouter surface of the core and does not extend upwardly past the outersurface of the core.

In step 351, a temperature resistant squeaker is inserted in theaperture formed in the core. The squeaker is formed of a material,preferably a polymer, that will not melt or deform at the elevatedtemperature at which the core-adhesive-felt typically are heated to cureor otherwise affect the rubber adhesive or other adhesive used to securethe felt or other fabric to the core. Using such a temperature resistantsqueaker significantly simplifies the process of producing an animal toythat includes a squeaker. As used herein with respect to the material(s)comprising a squeaker, a squeaker is temperature resistant if itfunctions normally after being subjected to the elevated temperatureapplied to the felt and adhesive to cure or otherwise affect a physicalproperty of the adhesive to facilitate securing the felt to the core.While the shape and dimension of the temperature resistant squeaker canvary as desired, it is presently preferred that the squeaker include areed 342 that vibrates when air passes over the reed and that isfabricated from a temperature resistant material. A temperatureresistant reed squeaker apparently has not been utilized to facilitatethe manufacture of a fabric covered squeaker toy for animals.

After the temperature resistant squeaker is inserted in the core, rubberadhesive or another desired adhesive or fastening material is applied tothe outer surface of the rubber core in step 352. A layer of felt isapplied to the layer of adhesive in step 353. In step 354, thecore-adhesive-felt is compressed and heated, typically to about 300degrees F., to cure the rubber adhesive and to compact and smooth thelayer of felt to make it more difficult for an animal to tear the feltoff the rubber core.

The ability to produce an animal toy according to the method set forthin FIG. 30 was a surprising result because it had been suggested thatattempting to heat a squeaker would not work because the heat would meltor deform the squeaker. It was discovered that it was feasible toproduce a squeaker from a polymer that would not melt at the elevatedtemperature used to compress and cure the adhesive that secured the feltto the core and to compress and cure the adhesive that was used to formseams between pieces of felt that were attached to the core. Using sucha temperature resistant squeaker significantly reduces the time requiredto produce a felt covered squeaker animal toy. A particular advantage ofusing the temperature resistant squeaker is that the felt layer on thecompleted toy is substantially continuous, which makes it more difficultfor an animal to locate the squeaker and remove the squeaker from thetoy. When a piece of felt is removed to insert the squeaker and is thenglued back in place over the squeaker, it is easier for an animal tolocate the squeaker. Another feature that makes it more difficult for ananimal to locate and remove the squeaker is countersinking the head ofthe squeaker in the manner earlier described herein. A further featurethat makes it more difficult for an animal to remove the squeaker isusing a squeaker 330 that has a tapered base 353. The base 353 has adiameter greater than that of the aperture formed in the core of thetoy, and has a lip 354, both of which make removal of the squeaker fromthe core difficult. Still another feature that makes it more difficultfor an animal to remove the squeaker is to utilize in the core areinforced, stronger area 413 (FIG. 18) around the squeaker that isthicker than other areas of the wall of the core.

Another method for making a toy of the general type illustrated in FIGS.18 to 28 is illustrated in FIG. 31. In step 358, a compressiblyelastically deformable spherical hollow thin-walled rubber (or otherelastomer) core is provided. The core includes an aperture shaped anddimensioned to function as a squeaker and to produce noise when airmoves through the aperture. Forming the aperture in this manner obviateshaving to later insert a squeaker in the core. The aperture can beformed in any desired manner, including by drilling or by being formedwhen the core (or a part of the core) is formed in a mold. The shape anddimension of the core can vary as desired and need not be spherical.

In step 359, adhesive is applied to the exterior of the rubber core,after which a layer of felt is applied in step 359. If the felt has anadhesive backing, then step 359 can be skipped and adhesive need not beapplied to the outer surface of the rubber core. The core-adhesive-feltcombination is compressed, heated, and cured in step 361.

Another method for making a toy of the general type illustrated in FIGS.18 to 28 is illustrated in FIG. 32. In step 364, a compressiblyelastically deformable spherical hollow thin-walled rubber (or otherelastomer) core is provided. The core includes an aperture 408 shapedand dimensioned to receive a squeaker. The aperture does not, however,extend completely through the wall of the core. Instead, a thinmembrane-indicated by dashed lines 408A in FIG. 18—extends across aportion of aperture 408. Membrane 408A ensures that the interior of thecore is sealingly enclosed. As described below, when a squeaker 307 isinserted in the aperture 408, the membrane 408A is punctured. Themembrane can be fabricated from any material including a polymer, paper,etc.

The aperture 408 can be formed in any desired manner, including bydrilling or by being formed when the core (or a part of the core) isformed in a mold. Since the formation of a membrane 408A is required,molding is believed to be a more likely alternative for forming aperture408. The shape and dimension of the core can vary as desired and neednot be spherical. While not necessary, the aperture preferably includesan inset or countersunk portion similar to the inset portion 409illustrated in FIG. 18. The cap or top 400 of the squeaker 307 seats insuch inset portion so that the top 400 of the squeaker 307 is flush withthe outer surface of the core.

In step 365, adhesive is applied to the exterior of the rubber core,after which a layer of felt is applied in step 366. Thecore-adhesive-felt combination is heated in step 367, after which anopening is formed in the felt in step 368. The opening is inregistration with the aperture formed in the core. The opening is madeby cutting through the felt and removing felt from adjacent theaperture. A squeaker 307 is inserted in the opening in the core in step369. The squeaker 307 punctures membrane 408A and extends into theinterior of the rubber core. In step 370, a piece of felt is glued overthe top 400 of the squeaker 307 to disguise the location of thesqueaker. An iron or other instrument is used in step 371 to flatten andsmooth the piece of felt. The opening in the felt during step 368 (orduring step 344 in a method earlier described herein) can also comprisea slit that is large enough to permit a squeaker 307 to be insertedthrough the slit and into the aperture formed in the core. After thesqueaker 307, the slit can be left “as is”, since the slit normally isquite small. Or, a small amount of glue can be applied and a needle orother instrument used to pull or displace felt back together along thelength of the slit. Or a small comb can be used, with or withoutapplying an adhesive to felt near the slit, move felt fibers into aposition crossing over and covering the slit. Or, an iron can be used,with or without glue or combing or using a needle, to flatten the feltfibers on either side of the slit.

The squeaker animal toys depicted in FIGS. 14, 21, 25, and 28 can, ifdesired, include one or more other openings formed through the wall ofthe core to receive other squeakers, to receive the end of a rope, or toreceive any other object incorporated in the toy.

The squeaker animal toy cores depicted in FIGS. 14, 21, 25, and 28 aresubstantially hollow. The hollow gas filled interior of each of thecores comprises a large part of the overall volume or space occupied bythe core. If desired, the interior of the core of each of the toys—orall or a selected part or parts of the material comprising each core—canconsist of foam, of a honeycomb-shaped lattice, of solid rubber or ofany other desired material or structure. For example, the spherical (orother shaped) core can be filled with foam or some other material, or,can consist completely of urethane foam, of solid rubber, or of someother material. If desired, a hollow can be formed in or through thesolid core to receive a squeaker. Adhesive and a fabric cover areattached to the solid core in the manner earlier described with respectto hollow thin-walled cores. If desired, felt or another fabric can beattached to a core with an adhesive or other fastening system that doesnot require heating the fabric or core or adhesive. The core can bepliable or elastic. If a polymer foam is used to fabricate all or a partof the core, the foam can be rigid and hard, soft and pliable, elastic,etc. as desired.

Any conventional squeaker can be utilized in a core. One conventionalhollow squeaker is self-contained and comprises a hollow bottle-shapedelastic pliable polymer member with a squeaker mounted in the “neck” or“top” of the bottle. The neck is attached to and is in gaseouscommunication with the hollow body or bladder of the squeaker. When thehollow body of the polymer member is squeezed and compressed from itsoriginal shape, air inside the body of the polymer member is forced outthrough the squeaker to produce sound. When the body is released (afterbeing squeezed), the body elastically returns to its original hollowshape and draws air through the squeaker and back into the body. Thiskind of conventional squeaker is sometimes used in plush toys.

Having set forth the presently preferred embodiments of our invention insuch terms as to enable those skilled in the art to make and use theinvention,

1. A method for producing an animal toy, including the steps of (a)forming a core of the toy including (i) an aperture, (ii) an exterior,and (iii) a thin puncturable sheet of material covering said aperture;(b) applying adhesive to said exterior of said core; (c) applying afabric cover to said exterior of said core in contact with saidadhesive; (d) providing a hollow sound device; (e) forming an opening insaid fabric cover in registration with said aperture by removing felt bycutting felt from above said aperture; (f) inserting said hollow sounddevice through said opening in said fabric cover and into said apertureto puncture said sheet and to produce a sound audible to a dog when airtravels through said sound device at a selected rate of flow; (g) gluingreplacement felt above said aperture; and, (h) flattening and smoothingsaid replacement felt.
 2. A method for producing an animal toy,including the steps of (a) forming a core of the toy including (i) anaperture, (ii) an exterior, and (iii) a thin puncturable sheet ofmaterial covering said aperture; (b) applying adhesive to said exteriorof said core; (c) applying a fabric cover to said exterior of said corein contact with said adhesive; (d) providing a hollow sound device; (e)forming a slit opening in said fabric cover in registration with saidaperture, said opening shaped and dimensioned to permit said hollowsound device to be inserted through said opening into said aperture;and, (f) inserting a hollow sound device through said opening in saidfabric cover and into said aperture to puncture said sheet and toproduce a sound audible to a dog when air travels through said sounddevice at a selected rate of flow.
 3. A method for producing an animaltoy, including the steps of (a) forming a core of the toy including (i)an aperture, (ii) an exterior, and (iii) a thin puncturable sheet ofmaterial covering said aperture; (b) applying adhesive to said exteriorof said core; (c) applying a fabric cover to said exterior of said corein contact with said adhesive, said fabric including fibers; (d)providing a hollow sound device; (e) forming a slit opening in saidfabric cover in registration with said aperture, said opening and shapedand dimensioned to permit said hollow sound device to be insertedthrough said opening into said aperture; (f) inserting a hollow sounddevice through said opening in said fabric cover and into said apertureto puncture said sheet and to produce a sound audible to a dog when airtravels through said sound device at a selected rate of flow; and, (g)moving some of said fibers of said fabric to cover said opening.